General Information - Toro Groundsmaster 455-D Service Manual

Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 3
Hydraulic Hose and Fitting Information . . . . . . . . 3
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . 5
Two (2) Wheel Drive . . . . . . . . . . . . . . . . . . . . . . 5
Four (4) Wheel Drive . . . . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC FLOW DIAGRAMS . . . . . . . . . . . . . . . 7
General Auxiliary Pump Flow . . . . . . . . . . . . . . . 7
Traction Circuit - Forward . . . . . . . . . . . . . . . . . . 8
Lift/Lower Circuit - Lifting Cutting Unit . . . . . . . . . 9
Steering Circuit - R.H. Turn . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . 11
Hydraulic Tester. . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . 13
System Operates Hot . . . . . . . . . . . . . . . . . . . . 13
Machine Travels in One Direction Only . . . . . . . 13
Traction Response is Sluggish . . . . . . . . . . . . . 14
Machine Will Not Travel in Either Direction . . . . 14
Four Wheel Drive Does Not Engage . . . . . . . . . 15
Four Wheel Drive Does Not Disengage . . . . . . 15
Cutting Unit(s) Do Not Lift or Lift Too Slowly . . . 16
Cutting Units Will Not Drop
or Follow Ground Contours . . . . . . . . . . . . . . 17
Cutting Unit(s) Drop From Raised Position
With Lift Valve in Centered Position . . . . . . . 17
Cutting Unit(s) Lower or Raise Too Quickly. . . . 18
Steering Loss . . . . . . . . . . . . . . . . . . . . . . . . . . 18
®
Groundsmaster 455-D
Hydraulic System
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Test No. 1: Checking Traction Circuit
Working Pressure or Relief Pressure. . . . . . . 20
Test No. 2: Checking Counterbalance Pressure 21
Test No. 3: Checking Wing Deck
Counterbalance Pressure . . . . . . . . . . . . . . . 22
Test No. 4: Checking Steering Circuit
Working Pressure or Relief Pressure. . . . . . . 23
Test No. 5: Checking Lift Circuit
Working Pressure or Relief Pressure. . . . . . . 24
Test No. 6: Checking Charge Pressure
For Traction Circuit. . . . . . . . . . . . . . . . . . . . . 25
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Traction Pump Neutral Adjustment . . . . . . . . . . 26
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removing Hydraulic System Components . . . . 27
Traction Pump Shaft Seal Replacement . . . . . . 28
Traction Pump Trunnion Seal Replacement . . . 29
Traction Pump Check and
High Pressure Relief Valves . . . . . . . . . . . . . 30
Traction Pump Charge Pressure Relief Valve . . 31
Disassembly of Traction Pump . . . . . . . . . . . . . 32
Assembly of Traction Pump. . . . . . . . . . . . . . . . 34
Auxiliary/Steering Pump Repairs. . . . . . . . . . . . 36
Front Traction Motor Repairs. . . . . . . . . . . . . . . 40
Rear Axle 4wd Motor Repairs . . . . . . . . . . . . . . 46
Lift Valve Repairs. . . . . . . . . . . . . . . . . . . . . . . . 48
Steering Control Unit Repairs . . . . . . . . . . . . . . 50
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Chapter 4
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